JP7279007B2 - Articles of footwear incorporating knitted components - Google Patents

Description

The present invention relates to articles of footwear incorporating knitted components.

A conventional article of footwear generally includes two major elements, an upper and a sole structure. The upper is secured to the sole structure and forms a cavity within the footwear for comfortably and stably receiving the foot. A sole structure is secured to the lower region of the upper so that it lies between the upper and the ground. For example, in athletic footwear, the sole structure may include a midsole and an outsole. The midsole may include a polymer foam material that dampens ground reaction forces to reduce stress on the foot and leg during walking, running and other walking activities. Additionally, the midsole may include liquid-filled chambers, plates, moderators, or other elements that further dampen force, enhance stability, or influence foot motion. The outsole is secured to the underside of the midsole and provides a ground anchoring portion of the sole structure formed of a durable, abrasion resistant material such as rubber. The sole structure may also include an insole positioned within the cavity and adjacent the underside of the foot to enhance the comfort of the footwear.

The upper generally extends over the instep and toe areas, along the medial and lateral sides of the foot, and around the heel area of the foot. In some articles of footwear, such as basketball footwear and boots, the upper may extend upwardly and around the ankle to provide support or protection to the ankle. Access to the interior cavity of the upper is generally provided by an ankle opening in the heel area of the footwear. To adjust the comfort of the upper, a lacing system is often incorporated into the upper that allows the foot to enter and exit a cavity within the upper. The lacing system also allows the wearer to adjust the particular dimensions of the upper, particularly the circumference, to accommodate different sized feet. Additionally, the upper may include a tongue that extends under the lacing system to increase the adjustability of the footwear, and the upper may incorporate a heel counter to limit heel movement.

A variety of material elements (eg, textiles, polymer foams, polymer sheets, leather, synthetic leather) are conventionally utilized in manufacturing uppers. For example, in athletic footwear, the upper may have multiple layers, each layer including various bonding material elements. By way of example, material elements may be selected to impart stretch resistance, abrasion resistance, flexibility, breathability, compression, comfort and quick drying properties to different areas of the upper. To impart different properties to different areas of the upper, the material elements are often cut to desired shapes and then joined together, usually by sewing or adhesive. Also, material elements are often joined in layered configurations to impart multiple properties to the same area. As the number and variety of material elements incorporated into the upper increase, the time and expense associated with shipping, storing, cutting and joining the material elements may also increase. Waste materials from the cutting and sewing process also accumulate more as the number and variety of material elements incorporated into the upper increase. Additionally, the greater number of material elements in an upper may be more difficult to recycle than uppers formed from fewer types and fewer material elements. As such, reducing the number of material elements utilized in the upper could reduce waste while increasing manufacturing efficiency and recyclability of the upper.

An article of footwear is disclosed below having an upper and a sole structure secured to the upper. The knitted component of the upper includes fusible and non-fusible yarns that are knitted together to form a plurality of intermeshing loops that define courses and wales. The knitted component also includes inlaid strands extending along at least one of the courses.

The following description also discloses an article of footwear having an upper that includes knit elements, inlaid strands and laces. The knit element defines a portion of the outer surface of the upper and an opposing inner surface of the upper, the inner surfaces defining a cavity for receiving the foot. A knit element extends from a throat area of the upper to a lower area of the upper, the knit element defining a plurality of openings located within the throat area. The inlay strands extend through the knit element from the throat area to the lower area. The inlaid strands also extend at least partially around the opening of the throat section, and the inlaid strands are positioned between the outer surface and the inner surface of the throat section. A lace extends through the opening.

Further disclosed below is an article of footwear having an upper that includes a first knit layer, a second knit layer, and a plurality of floating yarns. A first knit layer forms at least a portion of the outer surface of the upper. the second knit layer forming a unitary knit structure with the first knit layer, the second knit layer being positioned adjacent to the first knit layer and at least partially coextensive with the first knit layer; A tube is defined between the first knit layer and the second knit layer. A floating yarn is disposed within the tube and extends in a direction substantially parallel to the first knit layer and the second knit layer. Also, the first knit layer and the second knit layer are at least partially formed from yarns having an elongation of at least one hundred percent.

The advantages and features of novelty characterizing various aspects of the invention are pointed out with particularity in the appended claims. To gain a better understanding of the advantages and features of novelty, however, reference may be made to the following descriptive matter and accompanying drawings that describe and illustrate various configurations and concepts related to the present invention.

The above summary and the following detailed description will be better understood when read in conjunction with the accompanying drawings.

1 is a perspective view of an article of footwear; FIG. 1 is an elevational view of the outer side of an article of footwear; FIG. 1 is an elevational view of the medial side of an article of footwear; FIG. Figure 4 is a cross-sectional view of the article of footwear defined by section line 4A of Figures 2 and 3; 4B is a cross-sectional view of the article of footwear defined by section line 4B of FIGS. 2 and 3; FIG. 4C is a cross-sectional view of the article of footwear defined by section line 4C of FIGS. 2 and 3; FIG. 1 is a top plan view of a first knitted component forming part of an article of footwear upper; FIG. Fig. 3 is a bottom plan view of the first knitted component; 7A is a cross-sectional view of the first knitted component defined by section line 7A of FIG. 5; FIG. 7B is a cross-sectional view of the first knitted component defined by section line 7B of FIG. 5; FIG. 7C is a cross-sectional view of the first knitted component defined by section line 7C of FIG. 5; FIG. 7D is a cross-sectional view of the first knitted component defined by section line 7D in FIG. 5; FIG. 7E is a cross-sectional view of the first knitted component defined by section line 7E of FIG. 5; FIG. FIG. 4 is a plan view showing the knit structure of the first knitted component; FIG. 4 is a plan view showing the knit structure of the first knitted component; Fig. 4 is a top plan view of a second knitted component that may form part of the upper of the article of footwear; Fig. 10 is a bottom plan view of the second knitted component; FIG. 4 is a schematic top plan view of a second knitted component showing knit zones; 12A is a cross-sectional view of the second knitted component defined by section line 12A in FIG. 9; FIG. 12B is a cross-sectional view of the second knitted component defined by section line 12B in FIG. 9; FIG. 12C is a cross-sectional view of the second knitted component defined by section line 12C in FIG. 9; FIG. 12D is a cross-sectional view of the second knitted component defined by section line 12D in FIG. 9; FIG. 12E is a cross-sectional view of the second knitted component defined by section line 12E in FIG. 9; FIG. FIG. 4 is a loop diagram of a knit zone; FIG. 4 is a loop diagram of a knit zone; FIG. 4 is a loop diagram of a knit zone; FIG. 4 is a loop diagram of a knit zone; FIG. 4 is a loop diagram of a knit zone; FIG. 4 is a loop diagram of a knit zone; FIG. 4 is a loop diagram of a knit zone; FIG. 4 is a loop diagram of a knit zone; FIG. 6 is a top plan view corresponding to FIG. 5 and showing a further configuration of the first knitted component; FIG. 6 is a top plan view corresponding to FIG. 5 and showing a further configuration of the first knitted component; FIG. 6 is a top plan view corresponding to FIG. 5 and showing a further configuration of the first knitted component; 1 is a perspective view of a knitting machine; FIG. Fig. 3 is an elevational view of the combination feeder as seen from the knitting machine; Fig. 3 is an elevational view of the combination feeder as seen from the knitting machine; Fig. 3 is an elevational view of the combination feeder as seen from the knitting machine; Figure 17 is an elevational view corresponding to Figure 16, showing the internal components of the combination feeder; FIG. 20 is an elevational view corresponding to FIG. 19, showing operation of the combination feeder; FIG. 20 is an elevational view corresponding to FIG. 19, showing operation of the combination feeder; FIG. 20 is an elevational view corresponding to FIG. 19, showing operation of the combination feeder; 1 is a schematic perspective view of a knitting process utilizing a combination feeder and a conventional feeder; FIG. 1 is a schematic perspective view of a knitting process utilizing a combination feeder and a conventional feeder; FIG. 1 is a schematic perspective view of a knitting process utilizing a combination feeder and a conventional feeder; FIG. 1 is a schematic perspective view of a knitting process utilizing a combination feeder and a conventional feeder; FIG. 1 is a schematic perspective view of a knitting process utilizing a combination feeder and a conventional feeder; FIG. 1 is a schematic perspective view of a knitting process utilizing a combination feeder and a conventional feeder; FIG. 1 is a schematic perspective view of a knitting process utilizing a combination feeder and a conventional feeder; FIG. 1 is a schematic perspective view of a knitting process utilizing a combination feeder and a conventional feeder; FIG. 1 is a schematic perspective view of a knitting process utilizing a combination feeder and a conventional feeder; FIG. FIG. 3A is a schematic cross-sectional view of a knitting process showing the location of a combination feeder and a conventional feeder; FIG. 3A is a schematic cross-sectional view of a knitting process showing the location of a combination feeder and a conventional feeder; FIG. 3A is a schematic cross-sectional view of a knitting process showing the location of a combination feeder and a conventional feeder; FIG. 4 is a schematic perspective view showing another aspect of the knitting process; Fig. 3 is a perspective view of another configuration of the knitting machine;

The following description and accompanying drawings disclose various concepts relating to knitted components and their manufacture. Although knitted components may be utilized in a variety of products, an article of footwear incorporating one of the knitted components is disclosed below as an example. In addition to footwear, knitted components are used in other types of apparel (e.g., shirts, pants, socks, outerwear, underwear), athletic articles (e.g., golf bags, baseball and football gloves, soccer ball control structures). body), containers (eg, backpacks, bags), and furniture upholstery (eg, chairs, sofas, car seats). Knitted components may be utilized in bed coverings (eg, sheets, blankets), table coverings, towels, flags, tents, sails and parachutes. Knitted components are used in structures for the automotive and aerospace industries, filter materials, medical fabrics (e.g. bandages, swabs, grafts), geotextiles for embankment reinforcement, agrotextiles for crop protection , and industrial technical textiles, including industrial clothing that protects or insulates from heat and radiation. Accordingly, the knitted components and other concepts disclosed herein may be incorporated into a variety of products for both personal and industrial purposes.

Footwear Configuration An article of footwear 100 including a sole structure 110 and an upper 120 is illustrated in FIGS. 1-4C. Although footwear 100 is depicted as having a general configuration suitable for running, concepts associated with footwear 100 include, for example, baseball shoes, basketball shoes, cycling shoes, football shoes, tennis shoes, soccer shoes, training shoes. , walking shoes, and hiking boots, as well as various other athletic footwear types. This concept may also be applied to types of footwear generally considered non-athletic, including dress shoes, loafers, sandals and work shoes. Accordingly, the concepts disclosed with respect to footwear 100 apply to a wide variety of footwear types.

For reference, footwear 100 may be divided into generally three regions: toe region 101 , midfoot region 102 and heel region 103 . Forefoot region 101 generally includes the portion of footwear 100 corresponding to the toes and joints connecting the metatarsals and phalanges. Midfoot region 102 generally includes the portion of footwear 100 that corresponds to the arch area of the foot. Heel region 103 generally corresponds to the rear portion of the foot, including the calcaneus. Footwear 100 also includes a lateral side 104 and a medial side 105 that extend through each of regions 101 - 103 and correspond to opposite sides of footwear 100 . More specifically, lateral side 104 corresponds to the lateral portion of the foot (i.e., the surface facing away from the opposite foot) and medial side 105 corresponds to the medial portion of the foot (i.e., the surface facing away from the opposite foot). ). Regions 101 - 103 and sides 104 - 105 are not intended to demarcate precise areas of footwear 100 . Rather, regions 101-103 and sides 104-105 are intended to represent general areas of footwear 100 to aid in the discussion below. In addition to footwear 100, regions 101-103 and sides 104-105 may apply to sole structure 110, upper 120, and individual elements thereof.

Sole structure 110 is secured to upper 120 and extends between the foot and the ground when footwear 100 is worn. The primary elements of sole structure 110 are midsole 111 , outsole 112 and insole 113 . Midsole 111 is secured to the underside of upper 120 to dampen ground reaction forces (i.e., It may also be formed from a compressible polymeric foam element (eg, polyurethane or ethyl vinyl acetate foam) that provides cushioning. In further configurations, the midsole 111 may incorporate plates, moderators, liquid-filled chambers, lasting elements, or motion control members that further reduce force, increase stability, influence foot motion, or incorporate midsole 111 may be formed primarily of liquid-filled chambers. Outsole 112 is secured to the underside of midsole 111 and may be formed from a wear-resistant rubber material that is woven to provide traction. Insole 113 is positioned within upper 120 and positioned to extend below the underside of the foot to enhance the comfort of footwear 100 . Although this configuration of sole structure 110 provides one example of a sole structure that may be used in connection with upper 120, various other conventional or non-conventional configurations of sole structure 110 may also be utilized. may Accordingly, the characteristics of sole structures utilized with sole structure 110 or upper 120 may vary significantly.

Upper 120 defines a cavity within footwear 100 for receiving and securing the foot to sole structure 110 . The cavity is shaped to accommodate the foot and extends along the lateral side of the foot, along the medial side of the foot, over the foot, around the heel, and down the foot. Access to the cavity is provided by an ankle opening 121 located at least in heel region 103 . Laces 122 extend through various openings 123 in upper 120 to allow the wearer to adjust the dimensions of upper 120 to accommodate feet of various proportions. More specifically, the laces 122 allow the wearer to tighten the upper 120 around the foot, and the laces 122 allow the foot to enter and exit the wearer's cavity (i.e., through the ankle opening 121). For ease, upper 120 may be loosened. Additionally, upper 120 includes a lace 122 and tongue 124 that extends below opening 123 to enhance the comfort of footwear 100 . In a further configuration, upper 120 includes (a) a heel counter in heel region 103 to increase stability, (b) a toe guard formed of a wear-resistant material in forefoot region 101, and (c) logos, trademarks, and additional elements such as notes and tags with material information.

Many conventional footwear uppers are formed from multiple material elements (eg, textiles, polymer foams, polymer sheets, leather, synthetic leather) that are joined together, for example, by sewing or gluing. In contrast, the majority of upper 120 is formed from knit component 130, through each of regions 101-103, along both lateral side 104 and medial side 105, over forefoot region 101, It also extends around the heel area 103 . In addition, knit component 130 forms part of both the outer surface and the opposing inner surface of upper 120 . As such, knit component 130 defines at least a portion of a cavity within upper 120 . In some configurations, knitted component 130 may also extend under the foot. However, referring to FIGS. 4A-4C, a strobelled insole 125 is secured to the upper surface of knitted component 130 and midsole 111, thereby forming a portion of upper 120 that extends below insole 113. are doing.

Knitted Component Construction In FIGS. 5 and 6, knitted component 130 is shown separate from the rest of footwear 100 . Knitted component 130 is formed from a unitary knit construction. As utilized herein, a knitted component (eg, knitted component 130) is defined as being formed from a "unitary knit construction" when formed as a one-piece element in a knitting process. That is, the knitting process substantially forms the various features and structures of knitted component 130 without the need for significant additional manufacturing steps or processes. Although portions of knitted component 130 may be joined together after the knitting process (e.g., joining edges of knitted component 130 together), knitted component 130 is formed as a one-piece knitted element and is therefore still integral. It remains formed from the knit structure. Also, the knitted component 130 is still formed of unitary knit construction even with the addition of other elements after the knitting process (e.g., laces 122, tongue 124, logos, trademarks, notices and tags with material information). It remains.

The primary elements of knitted component 130 are knitted element 131 and inlay strand 132 . Knit element 131 is formed from at least one yarn that is manipulated (eg, using a knitting machine) to form a plurality of intermeshed loops that define various courses and wales. That is, knit element 131 has the structure of a knitted fabric. Inlaid strands 132 extend through knit element 131 and pass between various loops within knit element 131 . Although inlaid strands 132 generally extend along courses within knit element 131 , inlaid strands 132 may extend along wales of knit element 131 . Advantages of inlaid strands 132 include providing support, stability and structure. For example, the inlay strands 132 help secure the upper 120 around the foot, limit deformation in areas of the upper 120 (eg, provide stretch resistance), and work in conjunction with the laces 122 to tighten the footwear 100. Improve fit.

Knit element 131 has a generally U-shaped configuration delineated by a peripheral edge 133 , a pair of heel edges 134 and an inner edge 135 . When assembled into footwear 100 , peripheral edge 133 rests on top of midsole 111 and is joined to strobelled insole 125 . Heel edges 134 are joined together and extend perpendicular to heel region 103 . In some configurations of footwear 100 , material elements may cover the seams between heel edges 134 to reinforce the seams and enhance the aesthetic appeal of footwear 100 . Medial edge 135 defines ankle opening 121 and extends forward to an area where lace 122, opening 123 and tongue 124 are located. In addition, knit element 131 has a first side 136 and an opposing second side 137 . First surface 136 forms part of the outer surface of upper 120 , while second surface 137 forms part of the inner surface of upper 120 , thus defining at least part of a cavity within upper 120 .

As previously mentioned, inlaid strands 132 extend through knit element 131 and pass between various loops within knit element 131 . More specifically, inlaid strands 132 are disposed within the knit structure of knit element 131, which is in the area of inlaid strands 132 and faces 136 and 137, as illustrated in FIGS. 7A-7D. It may have a single fabric layer construction in between. As such, when knit component 130 is incorporated into footwear 100 , inlaid strands 132 are positioned between the exterior and interior surfaces of upper 120 . In some configurations, portions of inlaid strands 132 may be visible or exposed on one or both of surfaces 136 and 137 . For example, inlaid strand 132 may rest on one of surfaces 136 and 137, or knit element 131 may form a recess or opening through which the inlaid strand passes. An advantage of having inlaid strand 132 positioned between surfaces 136 and 137 is that knit element 131 protects inlaid strand 132 from chafing and snagging.

5 and 6, inlaid strands 132 extend from peripheral edge 133 toward inner edge 135, adjacent a side of one opening 123, around at least a portion of opening 123, and on the opposite side. , and then repeatedly extends back to the peripheral edge portion 133 . When knitted component 130 is incorporated into footwear 100, knitted element 131 moves from the throat area of upper 120 (i.e., where laces 122, opening 123 and tongue 124 are located) to the lower area of upper 120 (i.e., , where knit element 131 meets sole structure 110). In this configuration, inlaid strands 132 also extend from the throat area to the lower area. More specifically, the inlaid strand repeatedly passes through knit element 131 from the throat area to the lower area.

Knitted element 131 may be formed in a variety of ways, but the courses of the knitted structure extend in substantially the same direction as inlaid strands 132 . That is, the course may extend in a direction extending between the throat section and the lower section. As such, most of the inlaid strands 132 extend along a course within the knit element 131 . However, in areas adjacent openings 123 , inlaid strands 132 may extend along wales within knit element 131 . More specifically, a section of inlaid strand 132 parallel to inner edge 135 may extend along the wale.

As previously mentioned, the inlaid strand 132 is repeatedly passed through the knit element 131 . 5 and 6, inlaid strand 132 repeatedly exits knit element 131 at perimeter 133 and then re-enters knit element 131 at another location on perimeter 133, thereby A loop is formed along 133 . An advantage of this configuration is that each section of inlay strand 132 extending between the throat and lower sections may be independently tensioned, relaxed, or otherwise adjusted during the manufacturing process of footwear 100. . That is, the sections of the inlaid strands 132 may be independently adjusted for proper tension prior to securing the sole structure 110 to the upper 120 .

Compared to knit element 131, inlaid strand 132 may exhibit greater stretch resistance. That is, inlaid strand 132 may not stretch more than knit element 131 . Given that multiple sections of inlaid strands 132 extend from the throat region of upper 120 to the lower region of upper 120, inlaid strands 132 are stretch resistant in the portion of upper 120 between the throat region and the lower region. give sex. Tensioning of laces 122 may also impart tension to inlaid strands 132, thereby inducing portions of upper 120 between the throat and lower regions to rest against the foot. Inlaid strands 132 thus cooperate with laces 122 to enhance the fit of footwear 100 .

Knit element 131 may incorporate different types of yarns that impart different properties to individual areas of upper 120 . That is, an area of knit element 131 may be formed from yarns of a first type imparting a first set of properties, and another area of knit element 131 may be formed from yarns of a second type imparting a second set of properties. may be formed from In this configuration, selection of specific yarns in different areas of knit element 131 may vary properties throughout upper 120 . The properties that a particular type of yarn will impart to an area of knit element 131 depend in part on the materials forming the various filaments and fibers within the yarn. For example, cotton offers a soft feel, natural aesthetics, and biodegradability. Elastane and stretch polyester provide substantial stretch and recovery, respectively, and stretch polyester also offers recyclability. Rayon has good luster and provides moisture absorption. Wool also provides high moisture absorption in addition to insulating and biodegradable properties. Nylon is a durable, scratch resistant material with relatively high strength. Polyester is a hydrophobic material and also offers relatively high durability. In addition to materials, other aspects selected for knit element 131 may affect the properties of upper 120 . For example, the yarns forming knit element 131 may be monofilament or multifilament yarns. Yarns may include individual filaments each formed from a different material. In addition, the yarn may comprise individual filaments each formed from two or more different materials, such as a filament having a sheath-core configuration or a composite yarn using two types of filaments formed from different materials. Different degrees of twist and crimp, and different denier may also affect the properties of upper 120 . Accordingly, both the materials forming the yarns and other aspects of the yarns may be selected to impart various properties to individual areas of upper 120 .

As with the yarns forming knit element 131, inlaid strands 132 may also vary widely. In addition to yarns, inlaid strands 132 may have filament (eg, monofilament), thread, rope, band, cable, or chain configurations, for example. Inlaid strands 132 may be thicker than the yarns forming knit element 131 . In some configurations, inlaid strands 132 may have a thickness significantly greater than the yarns of knit element 131 . The cross-sectional shape of the inlaid strands 132 may be round, but may also utilize triangular, square, rectangular, oval or irregular shapes. Also, the material forming inlaid strands 132 may include any of the materials of the yarns in knit element 131, such as cotton, elastane, polyester, rayon, wool, and nylon. As previously mentioned, inlaid strands 132 may exhibit greater stretch resistance than knit element 131 . Thus, suitable materials for the inlaid strands 132 include glass, aramids (e.g., para-aramids and meta-aramids), ultra-high molecular weight polyethylene, and liquid crystal polymers for a variety of engineered filaments utilized in high tensile strength applications. may contain As another example, polyester braid may be utilized as the inlaid strands 132 .

An example of a suitable configuration for a portion of knitted component 130 is illustrated in FIG. 8A. In this configuration, knit element 131 includes yarns 138 forming a plurality of intermeshing loops defining a plurality of horizontal courses and vertical wales. The inlaid strands 132 extend along one of the courses and alternate (a) behind the loops formed from the yarns 138 and (b) in front of the loops formed from the yarns 138 . In practice, the inlay strand 132 weaves through the structure formed by the knit element 131 . Although yarns 138 form each of the courses in this configuration, additional yarns may form one or more of the courses, or may form part of one or more of the courses.

Another example of a suitable configuration for a portion of knitted component 130 is illustrated in FIG. 8B. In this configuration, knit element 131 includes yarn 138 and another yarn 139 . Yarns 138 and 139 are plated to collectively form a plurality of intermeshed loops that define a plurality of horizontal courses and vertical wales. That is, yarns 138 and 139 run parallel to each other. 8A, inlaid strand 132 extends along one of the courses (a) behind the loop formed from yarns 138 and 139 and (b) from yarns 138 and 139. are alternately placed before and between the loops that are An advantage of this configuration is that the respective properties of yarns 138 and 139 may be present in this area of knitted component 130 . For example, if the color of yarn 138 appears primarily on the surface of various stitches of knit element 131 and the color of yarn 139 appears primarily on the back of various stitches of knit element 131, yarns 138 and 139 are of different colors. may have As another example, if yarn 138 appears primarily on first side 136 and yarn 139 appears primarily on second side 137, yarn 139 is softer and more comfortable against the foot than yarn 138. may be formed from

Following the configuration of FIG. 8B, yarns 138 may be formed from at least one of thermoset polymers and natural fibers (e.g., cotton, wool, silk), while yarns 139 are formed from thermoplastic polymer materials. You may In general, thermoplastic polymeric materials melt when heated and return to a solid state when cooled. More specifically, a thermoplastic polymer material transitions from a solid state to a softened or liquid state when subjected to sufficient heat, and a thermoplastic polymer material transitions from a softened or liquid state to a solid state when cooled sufficiently. Transition. As such, thermoplastic polymer materials are often used to join two objects or elements. In this case, the yarns 139 may be, for example, (a) one portion of the yarns 138 to another portion of the yarns 138, (b) the yarns 138 and the inlaid strands 132 to each other, or (c) another element (e.g., logo , trademarks, and tags with cautionary and material information) may be utilized to join the knitted component 130 . As such, yarn 139 may be considered a fusible yarn if it may be used to fuse or otherwise join portions of knitted component 130 together. Yarns 138 may also be considered non-fusible yarns if they are not generally formed of a material capable of fusing or otherwise joining portions of knitted component 130 together. That is, yarn 138 may be a non-fusible yarn, while yarn 139 may be a fusible yarn. In some configurations of knitted component 130, yarns 138 (i.e., non-fusible yarns) may be formed substantially from a thermoset polyester material and yarns 139 (i.e., fusible yarns) are at least It may be partially formed from a thermoplastic polyester material.

The use of plated yarns may impart advantages to the knitted component 130 . When yarns 139 are heated to fuse yarns 138 and inlaid strands 132 , this process may have the effect of stiffening or stiffening the structure of knitted component 130 . Also, joining (a) one portion of the yarn 138 to another portion of the yarn 138 or (b) the yarn 138 and the inlaid strand 132 together fixes or locks the relative position of the yarn 138 and the inlaid strand 132. effect, thereby imparting stretch resistance and stiffness. That is, portions of yarn 138 do not slip relative to each other when fused with yarn 139, thereby preventing twisting or permanent stretching of knit element 131 due to relative movement of the knit structure. Another advantage involves limiting fraying if a portion of the knitted component 130 becomes damaged or one of the yarns 138 breaks. Also, inlaid strand 132 does not slip relative to knit element 131 , thereby preventing portions of inlaid strand 132 from being pulled outwardly from knit element 131 . Therefore, the area of knitted component 130 would benefit from the use of both fusible and non-fusible yarns in knitted element 131 .

Another aspect of knitted component 130 involves a padded area adjacent ankle opening 121 and extending at least partially around ankle opening 121 . Referring to FIG. 7E, the padded area may be formed from two overlapping, at least partially coextensive knit layers 140 and a plurality of knit layers 140 extending between the knit layers 140, which may be formed from a unitary knit construction. It is formed by floating yarns 141 . The sides and edges of knit layer 140 are secured together, but the central region is generally free. As such, the knit layers 140 effectively form a tube or tubular structure, and the floating yarns 141 may be positioned or interposed between the knit layers 140 to pass through the tubular structure. That is, the floating yarn 141 extends between the knit layers 140, is substantially parallel to the surfaces of the knit layers 140, and penetrates between the knit layers 140 to fill the internal space thereof. Although the majority of knit elements 131 are formed from machined yarns to form intermeshing loops, floating yarns 141 are generally free or otherwise interposed within the interior spaces between knit layers 140 . Additionally, knit layer 140 may be formed at least partially from stretch yarns. An advantage of this configuration is that the knit layer effectively compresses the floating yarns 141 and provides elastic properties to the padded area adjacent to the ankle opening 121 . That is, the stretch yarns in knit layer 140 may be placed in tension during the knitting process to form knitted component 130 , thereby inducing knit layer 140 to compress floating yarns 141 . Although the degree of stretchability of the stretch yarns may vary widely, in many configurations of knitted component 130 the stretch yarns may stretch at least one hundred percent.

The presence of floating yarns 141 imparts compressible properties to the padded area adjacent ankle opening 121 , thereby increasing the comfort of footwear 100 in the area of ankle opening 121 . Many conventional articles of footwear incorporate polymeric foam elements or other compressible materials in the area adjacent to the ankle opening. For conventional articles of footwear, the portion of knitted component 130 that forms from a unitary knit construction may, along with the remainder of knitted component 130 , form a padded area adjacent ankle opening 121 . Similar padded areas may be placed in other areas of knitted component 130 in further configurations of footwear 100 . For example, a similar padded area may be placed as the area corresponding to the joint between the metatarsal and proximal phalanx to provide padding for the joint. Alternatively, a terry loop construction may be utilized to provide a degree of padding in the upper 120 area.

Based on the above discussion, knitted component 130 provides upper 120 with various characteristics. Knitted component 130 also provides various advantages over some conventional upper constructions. As previously mentioned, conventional footwear uppers are formed from multiple material elements (eg, fabric, polymer foam, polymer sheet, leather, synthetic leather) that are joined, for example, by sewing or gluing. As the number and variety of material elements incorporated into the upper increase, so will the time and expense associated with shipping, storing, cutting and joining the material elements. Waste materials from the cutting and sewing process also accumulate more as the number and variety of material elements incorporated into the upper increase. Also, an upper with a high number of material elements will be more difficult to recycle than an upper formed from a lower variety and number of material elements. As such, reducing the number of material elements utilized in the upper will reduce waste while increasing manufacturing efficiency and recyclability of the upper. To this end, knitted component 130 forms a substantial portion of upper 120 while increasing manufacturing efficiency, reducing waste, and simplifying recyclability.

Additional Knitted Component Configurations Knitted component 150 is illustrated in FIGS. 9 and 10 and may be utilized in place of knitted component 130 of footwear 100 . The primary elements of knitted component 150 are knitted element 151 and inlaid strand 152 . Knit element 151 is formed from at least one yarn that is manipulated (eg, using a knitting machine) to form a plurality of intermeshing loops that define various courses and wales. That is, knit element 151 has the structure of a knitted fabric. Inlaid strands 152 extend through knit element 151 and pass between various loops within knit element 151 . Although inlaid strands 152 generally extend along courses within knit element 151 , inlaid strands 152 may extend along wales within knit element 151 . Like inlay strand 132 , inlay strand 152 provides stretch resistance and, when incorporated into footwear 100 , works in conjunction with laces 122 to enhance the fit of footwear 100 .

Knit element 151 has a generally U-shaped configuration delineated by a peripheral edge 153 , a pair of heel edges 154 and an inner edge 155 . Additionally, knit element 151 has a first side 156 and an opposing second side 157 . First surface 156 may form part of the exterior surface of upper 120 , while second surface 157 may form part of the interior surface of upper 120 , thus providing at least a portion of the cavity within upper 120 . define In many constructions, knit element 151 may have a single fabric layer construction in the area of inlaid strands 152 . That is, knit element 151 may be a single fabric layer between faces 156 and 157 . Additionally, knit element 151 defines a plurality of apertures 158 .

Similar to inlaid strand 132 , inlaid strand 152 repeatedly extends from peripheral edge 153 toward inner edge 155 , at least partially around one of openings 158 , and back to peripheral edge 153 . However, in contrast to inlaid strand 132 , a portion of inlaid strand 152 angles backward and extends to heel edge 154 . More specifically, the portion of inlay strand 152 associated with posterior-most opening 158 extends from one of heel edges 154 toward medial edge 155 and at least partially around posterior-most opening 158. , and also extends back to one of the heel edges 154 . Additionally, some portions of inlaid strand 152 do not extend around one of openings 158 . More specifically, some sections of the inlaid strands 152 extend toward the medial edge 155 and turn in an area adjacent one of the openings 158 to provide either peripheral edge 153 or heel edge 154 . It extends back toward one.

Knitted element 151 may be formed in a variety of ways, but the courses of the knitted structure extend generally in the same direction as inlaid strands 152 . However, in areas adjacent openings 158 , inlaid strands 152 may extend along wales within knit element 151 . More specifically, sections of inlaid strands 152 parallel to inner edge 155 may extend along the wales.

Compared to knit element 151, inlaid strand 152 may exhibit greater stretch resistance. That is, inlaid strand 152 does not have to stretch more than knit element 151 . If multiple sections of inlaid strands 152 extend through knit element 151, inlaid strands 152 may impart stretch resistance to portions of upper 120 between the throat and lower regions. Tensioning the laces 122 may also impart tension to the inlaid strands 152, thereby inducing portions of the upper 120 between the throat and lower regions to rest against the foot. Further, inlaid strands 152 may provide stretch resistance to portions of heel region 103 of upper 120 provided that multiple sections of inlaid strands 152 extend toward heel edge 154 . The lace 122 may also be tensioned to induce the portion of the upper 120 in the heel region 103 against the foot. Inlaid strands 152 thus cooperate with laces 122 to enhance the fit of footwear 100 .

Knit element 151 may incorporate any of the various types of yarns described above for knit element 131 . Inlaid strand 152 may also be formed from any of the configurations and materials described above for inlaid strand 132 . Additionally, the various knit configurations described with respect to FIGS. 8A and 8B may also be utilized in knitted component 150. FIG. More specifically, knit element 151 may have regions formed from a single yarn, two plated yarns, or fusible yarns and non-fusible yarns, and fusing The non-fusing yarn joins (a) one portion of the non-fusing yarn to another portion of the non-fusing yarn, or (b) the non-fusing yarn and the inlaid strand 152 to each other.

A majority of knit element 131 is illustrated as being formed from a relatively untextured fabric, a common or unitary knit structure (eg, tubular knit structure). In contrast, knit element 151 incorporates various knit constructions that impart specific properties and benefits to different areas of knit component 150 . Also, by combining different yarn types with the knit construction, knit component 150 may impart a wide range of properties to different areas of upper 120 . Referring to FIG. 11, a schematic diagram of knitted component 150 shows various zones 160-169 having different knit constructions, each of which will now be described in detail. For reference, in FIG. 11, regions 101-103 and sides 104 and 105, respectively, refer to the locations of knit zones 160-169 when knit component 150 is incorporated into footwear 100. showing.

A tubular knit zone 160 extends along most of the peripheral edge 153 and through each of the regions 101 - 103 of both sides 104 and 105 . A tubular knit zone 160 also extends inwardly from each of sides 104 and 105 in areas generally located at border regions 101 and 102 to form a forward portion of inner edge 155 . The tubular knit zone 160 forms a relatively untextured knit construction. Referring to FIG. 12A, a cross-section through the area of tubular knit zone 160 is illustrated, with faces 156 and 157 substantially parallel to each other. Tubular knit zone 160 provides footwear 100 with various benefits. For example, tubular knit zone 160 is more durable and abrasion resistant than some other knit constructions, especially when the yarns of tubular knit zone 160 are plated with fusible yarns. Additionally, the relatively untextured nature of tubular knit zone 160 simplifies the process of joining strobel insole 125 to perimeter 153 . That is, the portion of tubular knit zone 160 disposed along peripheral edge 153 facilitates the lasting process of footwear 100 . For reference, Figure 13A illustrates a loop diagram of how the tubular knit zone 160 is formed in the knitting process.

Two stretch-knit zones 161 extend from the peripheral edge 153 and are positioned to correspond to the location of the joint between the metatarsals and the proximal phalanges of the foot. That is, the stretch zones extend inwardly from the perimeter in areas that are generally located at border regions 101 and 102 . Similar to tubular knit zone 160, the knit construction of stretch knit zone 161 may be a tubular knit construction. However, in contrast to tubular knit zone 160 , stretch knit zone 161 is formed from stretch yarns that impart stretch and recovery to knitted component 150 . The degree of stretchability of the stretch yarns may vary widely, but in many configurations of knitted component 150 the stretch yarns may stretch at least one hundred percent.

A tubular double-sided tuck-knit zone 162 extends along at least a portion of the medial edge 155 of midfoot region 102 . Tubular double sided tuck knit zone 162 may also form a relatively untextured knit construction, but has a greater thickness than tubular knit zone 160 . In cross-section, tubular double-sided tuck-knit zone 162 is similar to Figure 12A, with faces 156 and 157 substantially parallel to each other. Tubular double-sided tuck-knit zone 162 provides footwear 100 with various benefits. For example, the tubular double-sided tuck knit zone 162 is more stretch resistant than some other knit constructions, which is advantageous when the laces 122 tension the tubular double-sided tuck knit zone 162 and the inlaid strands 152. . For reference, FIG. 13B illustrates a loop diagram of how the tubular double-sided tuck knit zone 162 is formed in the knitting process.

A knit zone 163 of 1×1 mesh is located in the forefoot region 101 and spaced inwardly from the perimeter 153 . The 1×1 mesh knit zone has a C-shaped configuration, forming a plurality of openings extending through the knit element 151 from the first side 156 to the second side 157, as shown in FIG. 12B. are doing. The openings increase the breathability of knitted component 150 , allowing air to enter upper 120 and moisture to escape from upper 120 . For reference, FIG. 13C illustrates a loop diagram of how the 1×1 mesh knit zone 163 is formed in the knitting process.

A knit zone 164 of 2×2 mesh extends adjacent to a knit zone 163 of 1×1 mesh. Compared to knit zones 163 of 1×1 mesh, knit zones 164 of 2×2 mesh will form larger openings, further enhancing the breathability of knitted component 150 . For reference, FIG. 13D illustrates a loop diagram of how the knitting process forms a knit zone 164 of 2×2 mesh.

A 3×2 mesh knit zone 165 is located within a 2×2 mesh knit zone 164 and another 3×2 mesh knit zone 165 is located adjacent one of the stretch zones 161 . Compared to the 1×1 mesh knit zone 163 and the 2×2 mesh knit zone 164, the 3×2 mesh knit zone 165 creates larger openings and will further enhance the breathability of the knitted component 150. . For reference, FIG. 13E illustrates a loop diagram of how a 3×2 mesh knit zone 165 is formed in a knitting process.

A knit zone 166 of 1×1 mock mesh is located in the forefoot region 101 and extends around a knit zone 163 of 1×1 mesh. In contrast to knit zones 163-165 of mesh forming openings through knit element 151, knit zone 166 of 1×1 mock mesh forms a recess in first face 156, as shown in FIG. 12C. In addition to enhancing the aesthetics of footwear 100, knit zones 166 of 1x1 mock mesh increase the flexibility of knitted component 150 and reduce overall mass. For reference, FIG. 13F illustrates a loop diagram of how the knitting process forms knit zones 166 of 1×1 mock mesh.

Two 2×2 mock mesh knit zones 167 are located in the heel area, adjacent to the heel edge 154 . A knit zone 167 of 2×2 mock mesh creates a larger depression in the first surface 156 as compared to a knit zone 166 of 1×1 mock mesh. As shown in FIG. 12D, in the areas where the inlaid strands 152 extend through the depressions of the knit zone 167 of the 2×2 mock mesh, the inlaid strands 152 should be visible and exposed in the lower areas of the depressions. deaf. For reference, FIG. 13G illustrates a loop diagram of how the knitting process forms knit zones 167 of 2×2 mock mesh.

Two 2x2 hybrid knit zones 168 are positioned in the midfoot region 102 in front of a 2x2 mock mesh knit zone 167 . The 2×2 hybrid knit zone 168 shares the characteristics of the 2×2 mesh knit zone 164 and the 2×2 mock mesh knit zone 167 . More specifically, the 2x2 hybrid knit zones 168 form openings having the size and configuration of the 2x2 mesh knit zones 164, while the 2x2 hybrid knit zones 168 are 2x2 mock mesh knit zones. Depressions with 167 sizes and configurations are formed. As shown in FIG. 12E, in areas where the inlaid strands 152 extend through the recesses of the 2×2 hybrid knit zones 168, the inlaid strands 152 are visible and exposed. For reference, Figure 13H illustrates a loop diagram of how the 2x2 hybrid knit zone 168 is formed in the knitting process.

Knit component 150 has two padded zones having a general configuration of padded areas adjacent to and extending at least partially around ankle opening 121 as described above for knit component 130 . 169 may be included. Thus, the padded zone 169 may be formed from two knit layers that may be formed from an overlapping, at least partially coextensive unitary knit structure and a plurality of floating yarns extending between the knit layers. formed by

A comparison with FIGS. 9 and 10 reveals that the majority of the texturing of knit element 151 is located on first side 156 and not on second side 157 . That is, the depressions formed by mock mesh knit zones 166 and 167 and the depression of 2×2 hybrid knit zone 168 are formed in first surface 156 . This configuration has the advantage of increasing the comfort of footwear 100 . More specifically, this configuration provides a relatively untextured configuration of second surface 157 against the foot. A further comparison of FIGS. 9 and 10 reveals that portions of the inlaid strands 152 are exposed on the first side 156 but not on the second side 157 . This configuration also has the advantage of increasing the comfort of footwear 100 . More specifically, by keeping the inlaid strand 152 away from the foot by a portion of the knit element 151, the inlaid strand 152 does not contact the foot.

Additional configurations of knitted component 130 are illustrated in FIGS. 14A-14C. Although described with respect to knitted component 130 , the concepts associated with each of these configurations may also be utilized with knitted component 150 . Referring to FIG. 14A, inlaid strands 132 are absent from knitted component 130 . Although inlaid strands 132 provide stretch resistance to areas of knitted component 130 , stretch resistance from inlaid strands 132 may not be required in some configurations. Also, some configurations may benefit from greater stretchability of upper 120 . Referring to FIG. 14B, knit element 131 is formed of unitary knit construction with the remainder of knit element 131 and includes two flaps extending along the length of knit component 130 at peripheral edge 133 . I'm in. When incorporated into footwear 100 , flaps 142 may replace strobel insole 125 . That is, flaps 142 may extend under insole 113 and collectively form a portion of upper 120 that is secured to the upper surface of midsole 111 . Referring to FIG. 14C, knit component 130 has a configuration that is confined to midfoot region 102 . In this configuration, other material elements (eg, fabric, polymer foam, polymer sheet, leather, synthetic leather) may be joined to the knit component 130, eg, by sewing or gluing, to form the upper 120.

Based on the above discussion, each of knitted components 130 and 150 may have various configurations that impart features and benefits to upper 120 . More specifically, knit elements 131 and 151 may incorporate various knit structures and yarn types that impart specific properties to different areas of upper 120, while inlaid strands 132 and 152 provide stretch resistant areas of upper 120. It may extend through the knit structure to add flexibility and cooperate with the laces 122 to enhance the fit of the footwear 100 .

Knitting Machine and Feeder Configurations Knitting may be done by hand, but commercial manufacturing of knitted components is generally done on knitting machines. One embodiment of a knitting machine 200 suitable for producing both knitted components 130 and 150 is illustrated in FIG. Although knitting machine 200 has a V-bed flat knitting machine configuration for purposes of illustration, either knitted components 130 and 150 or sides of knitted components 130 and 150 may be produced on other types of knitting machines. .

Knitting machine 200 includes two needle beds 201 that are angled with respect to each other to form a V-bed. Each needle bed 201 includes a plurality of individual needles 202 lying on a common plane. That is, needles 202 from one needle bed 201 lie in a first plane and needles 202 from the other needle bed 201 lie in a second plane. The first and second planes (ie, the two needle beds 201 ) are angled with respect to each other and meet to form an intersection that extends along most of the width of the knitting machine 200 . Needles 202 each have a first retracted position and a second extended position, as will be described in more detail below. In the first position, needle 202 is away from the intersection of the first and second planes. However, in the second position needle 202 passes through the intersection of the first and second planes.

A pair of rails 203 extend above and parallel to the intersection of needle beds 201 to provide attachment points for a plurality of standard feeders 204 and combination feeders 220 . Each rail 203 has two sides, each of which accommodates either one standard feeder 204 or one combination feeder 220 . Knitting machine 200 may thus include a total of four feeders 204 and 220 . As shown, the front row of rails 203 includes one combination feeder 220 and one standard feeder 204 on opposite sides, and the rearmost rail 203 includes two standard feeders 204 on opposite sides. . Although two rails 203 are illustrated, further configurations of knitting machine 200 may incorporate additional rails 203 to provide attachment points for more feeders 204 and 220 .

The action of carriage 205 causes feeders 204 and 220 to move along rail 203 and needle bed 201 , thereby feeding needles 202 with yarn. In FIG. 15, yarn 206 is being fed into combination feeder 220 by spool 207 . More specifically, yarn 206 extends from spool 207 to various yarn guides 208 , yarn pull springs 209 and yarn tensioners 210 before entering combination feeder 220 . Although not shown, an additional spool 207 may be utilized to supply yarn to feeder 204 .

A standard feeder 204 is conventionally utilized in V-bed type flat knitting machines, such as knitting machine 200 . That is, existing knitting machines incorporate standard feeders 204 . Each standard feeder 204 is capable of feeding yarns that are knitted, tucked and floated by needles 202 . By comparison, combination feeder 220 has the ability to feed yarns (eg, yarns 206) that are knitted, tucked and floated by needles 202, and has the ability to insert yarns. Combination feeder 220 also has the ability to insert a variety of different steps (eg filaments, threads, ropes, strips, cables, chains or yarns). Therefore, combination feeder 220 exhibits greater versatility than each standard feeder 204 .

As previously mentioned, the combination feeder 220 may be utilized when inserting yarns or other strands in addition to knitting, tucking and floating yarns. Conventional knitting machines that do not incorporate a combination feeder 220 may also insert yarn. More specifically, a conventional knitting machine fed with an inlay feeder may also insert the yarn. A conventional inlay feeder for a V-bed flat knitting machine includes two components that work together to insert the yarn. Each of the inlay feeder components is fixed to separate attachment points on two adjacent rails, thereby occupying two attachment points. Each standard feeder 204 occupies only one attachment point, whereas two attachment points are generally occupied when an inlay feeder is utilized to insert yarn into a knitted component. Also, the combination feeder 220 only occupies one mounting point, whereas the conventional inlay feeder occupies two mounting points.

If knitting machine 200 includes two rails 203, then four attachment points are available on knitting machine 200. As shown in FIG. If a conventional inlay feeder were utilized in knitting machine 200 , only two attachment points would be available for standard feeder 204 . However, using a combination feeder 220 with knitting machine 200 provides three attachment points for standard feeder 204 . Therefore, combination feeder 220 may be utilized when inserting yarn or other strands, and has the advantage that combination feeder 220 occupies only one attachment point.

A combination feeder 220 including a carrier 230, feeder arm 240 and a pair of actuating members 250 is illustrated separately in FIGS. 16-19. Although the majority of combination feeder 220 may be formed from metallic materials (eg, steel, aluminum, titanium), portions of carrier 230, feeder arm 240 and actuation member 250 may be formed from polymeric, ceramic or composite materials, for example. may As previously mentioned, the combination feeder 220 may be utilized when knitting, tucking and floating yarns, as well as inserting yarns or other strands. Referring specifically to FIG. 16, a portion of yarn 206 is shown to illustrate how the strands interface with combination feeder 220 .

Carrier 230 has a generally rectangular configuration and includes a first cover member 231 and a second cover member 232 joined by four bolts 233 . Cover members 231 and 232 define an internal cavity in which portions of feeder arm 240 and actuation member 250 are located. Carrier 230 also includes a mounting element 234 extending outwardly from first cover member 231 for securing feeder 220 to one of rails 230 . Although the configuration of mounting element 234 may vary, as illustrated in FIG. 17, mounting element 234 is illustrated as including two spaced apart flaring sections forming a dovetail shape. An inverted dovetail configuration on one of rails 203 may extend to the dovetail shape of mounting element 234 to effectively join combination feeder 220 to knitting machine 200 . It should also be noted that the second cover member 232 is centrally located to form an elongated slot 235, as shown in FIG.

Feeder arm 240 has a generally elongate configuration extending outwardly from the underside of carrier 230 (ie, the cavity between cover members 231 and 232). In addition to other elements, feeder arm 240 includes actuation bolt 241 , spring 242 , pulley 243 , loop 244 and yarn feed section 245 . Actuating bolt 241 extends outwardly from feeder arm 240 and is located within a cavity between cover members 231 and 232 . One side of the actuation bolt 241 is also located in the slot 235 of the second cover member 232, as shown in FIG. Spring 242 is fixed to carrier 230 and feeder arm 240 , more specifically, one end of spring 242 is fixed to carrier 230 and the other end of spring 242 is fixed to feeder arm 240 . A pulley 243, a loop 244 and a yarn feed section 245 are present on feeder arm 240 to interface yarn 206 or another strand. Also, pulleys 243 , loops 244 and yarn feed area 245 are configured to ensure that yarn 206 or another strand passes smoothly through combination feeder 220 , thereby feeding needles 202 . . Referring again to FIG. 16, yarn 206 extends around pulley 243 , through loop 244 and into yarn feed area 245 . Additionally, the yarn 206 extends from the distal region of the feeder arm 240 , the yarn feeding tip 246 , and is further fed to the needle 202 .

Each actuation member 250 includes an arm 251 and a plate 252 . In many configurations of actuating member 250, each arm 251 is formed with one of plates 252 as a one-piece element. Arm 251 is located outside and above carrier 230 , while plate 252 is located within carrier 230 . Each of the arms 251 has an elongated configuration defining an outer end 253 and an opposite inner end 254 , the arms 251 being positioned to define a space between the inner ends 254 . That is, the arms 251 are separated from each other. Plate 252 has a generally planar configuration. Referring to FIG. 19, each of plates 252 defines an aperture 256 with slanted edge 257 . Also, an actuation bolt 241 of feeder arm 240 extends into each opening 256 .

The combination feeder 220 configuration described above provides a structure that facilitates translational movement of the feeder arm 240 . Translation of feeder arm 240 selectively positions yarn feed tip 246 at a position above or below the intersection of needle beds 201, as will be described in more detail below. That is, the yarn feed tip 246 has the ability to reciprocate through the intersection of the needle beds 201 . An advantage of the translational movement of the feeder arm 240 is that the combination feeder 220 (a) moves the yarn 206 to knit, tuck and float when the yarn feeding tip 246 is positioned over the intersection of the needle bed 201; and (b) feeding the yarn 206 or another strand for insertion when the yarn feed tip 246 is positioned below the intersection of the needle bed 201 . The feeder arm 240 also reciprocates between two positions depending on the manner in which the combination feeder 220 is utilized.

In reciprocating across the intersection of needle beds 201, feeder arm 240 translates from a retracted position to an extended position. When in the retracted position, the yarn feed tip 246 is positioned above the intersection of the needle beds 201 . When in the stretched position, the yarn feed tip 246 is positioned below the intersection of the needle beds 201 . Feed tip 246 is closer to carrier 230 when feeder arm 240 is in the retracted position than when feeder arm 240 is in the extended position. Similarly, the feed tip 246 is farther from the carrier 230 when the feeder arm 240 is in the extended position than when the feeder arm 240 is in the retracted position. In other words, the yarn feed tip 246 moves away from the carrier 230 when in the extended position, and the yarn feed tip 246 moves closer to the carrier 230 when in the retracted position.

Arrow 221 is positioned adjacent yarn feed area 245 for reference in FIGS. 16-20C and further figures described later. When arrow 221 points upward or toward carrier 230, feeder arm 240 is in the retracted position. When arrow 221 points downward or away from carrier 230, feeder arm 240 is in the extended position. Therefore, by referring to the position of arrow 221, the position of feeder arm 240 will be readily ascertained.

The natural state of feeder arm 240 is the retracted position. That is, without applying any significant force to the area of combination feeder 220, feeder arm 240 remains in the retracted position. For example, referring to FIGS. 16-19, no forces or other influences interacting with combination feeder 220 are shown, with feeder arm 240 in the retracted position. However, application of sufficient force to one of the arms 251 causes translational movement of the feeder arm 240 . More specifically, when sufficient force is applied to one of the outer ends 253 to direct it into the space 255, translational movement of the feeder arm 240 occurs. 20A and 20B, force 222 is shown acting on one of outer ends 253 and directed into space 255, translating feeder arm 240 to the extended position. However, removal of force 222 causes feeder arm 240 to return to the retracted position. It should also be noted that FIG. 20C illustrates force 222 acting on inner end 254 when directed outward, feeder arm 240 remains in the retracted position.

As previously mentioned, feeders 204 and 220 move along rails 203 and needle beds 201 due to the action of carriage 205 . More specifically, a drive bolt within carriage 205 contacts feeders 204 and 220 to push feeders 204 and 220 along needle bed 201 . With regard to combination feeder 220 , the drive bolt contacts either one of outer ends 253 or one of inner ends 254 to push combination feeder 220 along needle bed 201 . When the drive bolt contacts one of the outer ends 253 , the feeder arm 240 translates to the extended position and the yarn feed tip 246 passes under the intersection of the needle beds 201 . When the drive bolt contacts one of the inner ends 254 and is positioned within the space 255 , the feeder arm 240 remains in the retracted position with the yarn feed tip 246 above the intersection of the needle beds 201 . Thus, the area where carriage 205 contacts combination feeder 220 determines whether feeder arm 240 is in the retracted or extended position.

The mechanical action of combination feeder 220 will now be described. 19-20B illustrate the combination feeder 220 with the first cover member 231 removed to expose the elements within the cavity of the carrier 230. FIG. By comparing FIG. 19 with FIGS. 20A and 20B, it will be apparent how force 222 induces feeder arm 240 to translate. When force 222 acts on one of outer ends 253 , one of actuating members 250 slides in a direction perpendicular to the length of feeder arm 240 . That is, the actuating member 250 slides horizontally in FIGS. 19-20B. One movement of actuating member 250 engages actuating bolt 241 with one of ramp edges 257 . If the motion of the actuating member 250 is constrained in a direction perpendicular to the length of the feeder arm 240, the actuating bolt 241 will rotate or slide against the beveled edge 257 to translate the feeder arm 240 to the extended position. lead to When force 222 is removed, spring 242 pulls feeder arm 240 from the extended position to the retracted position.

Based on the above description, the combination feeder 220 has retracted and extended positions depending on whether the yarn or other strand is being utilized for knitting, tucking, floating, or for insertion. and reciprocate. Combination feeder 220 has a configuration in which application of force 222 induces translation of feeder arm 240 from the retracted position to the extended position, and removal of force 222 induces translation of feeder arm 240 from the extended position to the retracted position. have. That is, combination feeder 220 has a configuration in which application and removal of force 222 cause feeder arm 240 to reciprocate between opposite sides of needle bed 201 . In general, the outer end 253 may be considered the working area and guides the movement of the feeder arm 240. In further configurations of combination feeder 220, the actuation area may be in other locations or may induce movement of feeder arm 240 in response to other stimuli. For example, the actuation area may be an electrical input coupled to a servomechanism that controls the movement of feeder arm 240 . Accordingly, the combination feeder 220 may have various constructions that operate in the same general manner as the constructions described above.

Knitting Process The manner in which knitting machine 200 operates to produce a knitted component will now be described in detail. Also, the following description demonstrates the operation of the combination feeder 220 during the knitting process. Referring to FIG. 21A, a portion of knitting machine 200 including various needles 202, rails 203, standard feeder 204 and combination feeder 220 is illustrated. The combination feeder 220 is fixed to the front side of the rail 203 while the standard feeder 204 is fixed to the rear side of the rail 203 . Yarn 206 passes through combination feeder 220 with one end of yarn 206 extending outward from yarn feed tip 246 . Although yarn 206 is shown, any other strand (eg, filament, thread, rope, band, cable, chain or yarn) may pass through combination feeder 220 . Another yarn 211 passes through a standard feeder 204 to form part of the knitted component 260 and the loop of yarn 211 forming the top course of the knitted component 260 is held by a hook located at the end of the needle 202. It is

The knitting process described herein involves forming knitted component 260 , which may be any knitted component, including knitted components similar to knitted components 130 and 150 . For illustrative purposes, the drawings show only a relatively small section of the knitted component 260 so as to illustrate the knitted structure. Also, the scale or proportions of various elements of knitting machine 200 and knitted component 260 are exaggerated to better illustrate the knitting process.

A standard feeder 204 includes a feeder arm 212 with a feeding tip 213 . Feeder arm 212 is angled to position yarn feed tip 213 in a position that is (a) centered between needles 202 and (b) above the intersection of needle beds 201 . FIG. 22A illustrates a schematic cross-sectional view of this configuration. Note that the needles 202 are on different planes and are angled with respect to each other. That is, the needles 202 from the needle bed 201 are on different planes. Needles 202 each have a first position and a second position. In a first position, shown in solid lines, needle 202 is retracted. In a second position, shown in dashed lines, the needle 202 is extended. In the first position, the needle 202 is away from the intersection where the planes of the needle bed 201 meet. However, in the second position, the needle extends through the intersection where the planes of the needle bed 201 meet. That is, the needles 202 cross each other when extended to the second position. It should be noted that the yarn feed tip 213 is positioned above the intersection of the planes. In this position, yarn feed tip 213 feeds yarn 211 to needle 202 for knitting, tucking and floating.

Combination feeder 220 is in a retracted position as clearly shown by the orientation of arrow 221 . Feeder arm 240 extends downwardly from carrier 230 to position yarn feed tip 246 in a position that is (a) centered between needles 202 and (b) above the intersection of needle beds 201 . FIG. 22B illustrates a schematic cross-sectional view of this configuration. Note that yarn feed tip 246 is positioned in the same relative position as yarn feed tip 213 in FIG. 22A.

Referring now to FIG. 21B, standard feeder 204 has moved along rail 203 to form a new course from yarn 211 to knit component 260 . More specifically, needle 202 pulls a section of yarn 211 through the loops of the previous course, thereby forming a new course. Thus, a course is added to knit component 260 by moving standard feeder 204 along needle 202, thereby allowing needle 202 to manipulate yarn 211 to form additional loops from yarn 211. may

Continuing the knitting process, the feeder arm 240 now translates from the retracted position to the extended position, as illustrated in FIG. 21C. In the extended position, the feeder arm 240 extends downwardly from the carrier 230 to leave the feed tip 246 (a) centered between the needles 202 and (b) below the intersection of the needle beds 201. position. FIG. 22C illustrates a schematic cross-sectional view of this configuration. Note that yarn feed tip 246 is positioned below the location of yarn feed tip 246 in FIG.

Referring now to FIG. 21D, combination feeder 220 moves along rail 203 and yarn 206 is positioned between loops of knit component 260 . That is, the yarns 206 are arranged in an alternating pattern in front of some loops and behind others. Also, the yarn 206 is placed in front of the loop held by the needle 202 from one needle bed 201 and the yarn 206 is placed behind the loop held by the needle 202 from the other needle bed 201. ing. Note that the feeder arm 240 remains in the extended position to place the yarn 206 in the area below the intersection of the needle beds 201 . This effectively places the yarn 206 within the course previously formed by the standard feeder 204 of FIG. 21B.

To fully insert yarn 206 into knitted component 260, standard feeder 204 moves along rail 203 to form a new course from yarn 211, as illustrated in FIG. 21E. By forming new courses, yarns 206 are effectively knitted or otherwise integrated into the structure of knitted component 260 . At this stage, the feeder arm 240 may also translate from the extended position to the retracted position.

21D and 21E show separate movement of feeders 204 and 220 along rail 203. FIG. 21D shows a first movement of combination feeder 220 along rail 203, and FIG. 21E shows a second subsequent movement of standard feeder 204 along rail 203. FIG. In many knitting processes, feeders 204 and 220 may effectively move to form a new course from yarn 211 while simultaneously inserting yarn 206 . However, combination feeder 220 moves ahead of or in front of standard feeder 204 in order to position yarn 206 before forming a new course from yarn 211 .

The general knitting process outlined in the discussion above provides examples of how inlaid strands 132 and 152 may be arranged in knit elements 131 and 151 . More specifically, knitted components 130 and 150 may be formed by utilizing combination feeder 220 to effectively insert inlaid strands 132 and 152 into knitted element 131 . Given the reciprocating motion of the feeder arm 240, the inlaid strands may be placed within the previously formed course before forming the new course.

Continuing the knitting process, the feeder arm 240 now translates from the retracted position to the extended position, as illustrated in FIG. 21F. Combination feeder 220 then moves along rail 203 to place yarn 206 between the loops of knit component 260, as illustrated in FIG. 21G. This effectively places the yarn 206 within the course formed by the standard feeder 204 of FIG. 21E. To fully insert yarn 206 into knitted component 260, standard feeder 204 moves along rail 203 to form a new course from yarn 211, as illustrated in FIG. 21H. By forming new courses, yarns 206 are effectively knitted or otherwise integrated into the structure of knitted component 260 . At this stage, the feeder arm 240 may also translate from the extended position to the retracted position.

Referring to Figure 21H, the yarn 206 forms a loop 214 between the two inlay sections. In the description of knitted component 130 above, inlaid strand 132 repeatedly exits knit element 131 at perimeter 133 and then re-enters knit element 131 at different locations on perimeter 133, thereby re-entering FIG. Care was taken to form a loop along the perimeter 133 , as seen at 6 . Loop 214 is similarly formed. That is, loop 214 is formed where yarn 206 exits the knit structure of knitted component 260 and then re-enters the knit structure.

As explained above, standard feeder 204 is capable of feeding yarns (eg, yarns 211) that are knitted, tucked and floated by needles 202. FIG. However, the combination feeder 220 has the ability to insert yarns as well as feed yarns that are knitted, tucked or floated by the needles 202 (eg, yarns 206). The above description of the knitting process describes the manner in which the yarn is inserted while the combination feeder 220 is in the stretched position. Combination feeder 220 may supply yarn for knitting, tucking and floating when in the retracted position. Referring to FIG. 21I, for example, combination feeder 220 moves along rail 203 when in the retracted position and forms a course of knitted component 260 when in the retracted position. Thus, by reciprocating feeder arm 240 between retracted and extended positions, combination feeder 220 may feed yarn 206 for knitting, tucking, floating and interleaving. As such, the advantage of the combination feeder 220 relates to its versatility in supplying yarns that may be utilized for more functions than the standard feeder 204.

The ability of combination feeder 220 to feed yarn for knitting, tucking, floating and inserting is based on the reciprocating motion of feeder arm 240 . 22A and 22B, yarn feed tips 213 and 246 are in the same position relative to needle 220. FIG. Thus, feeders 204 and 220 may both supply yarn for knitting, tucking and floating. Referring to Figure 22C, the yarn feed tip 246 is in a different position. Thus, combination feeder 220 may supply yarn or other strands for insertion. As such, the advantage of the combination feeder 220 relates to its versatility in feeding yarns that may be utilized for knitting, tucking, floating and inlaying.

Further Knitting Process Considerations Additional aspects relating to the knitting process will now be discussed. Referring to FIG. 23, the upper course of knitted component 260 is formed from both yarns 206 and 211 . More specifically, the left side of the course is formed of yarn 211, while the right side of the course is formed of yarn 206. FIG. Additionally, yarn 206 is inserted on the left side of the course. To form this configuration, standard feeder 204 may first form the left side of the course from yarn 211 . Next, combination feeder 220 lays yarn 206 on the right side of the course when feeder arm 240 is in the extended position. Feeder arm 240 then moves from the extended position to the retracted position to form the right side of the course. Thus, the combination feeder 220 may insert yarn into one portion of the course and then feed the yarn for knitting the remaining portion of the course.

FIG. 24 illustrates a knitting machine 200 configuration that includes four combination feeders 220. As shown in FIG. As explained above, the combination feeder 220 has the ability to feed yarn (eg, yarn 206) for knitting, tucking, floating and intercalating. Given this versatility, the standard feeder 204 may be replaced by multiple combination feeders 220 in the knitting machine 200 or various conventional knitting machines.

FIG. 8B illustrates the construction of knitted component 130 in which two yarns 138 and 139 are plated to form knitted element 131 and inlaid strand 132 extends through knitted element 131 . The general knitting process described above may also be utilized to form this construction. As illustrated in FIG. 15, knitting machine 200 includes a plurality of standard feeders 204, two of which may be utilized to form knit element 131, and combination feeder 220 for inlaid strands. 132 is placed. Accordingly, the knitting process described above in Figures 21A-21I may be modified by adding another standard feeder 204 to supply additional yarns. In configurations where yarn 138 is a non-fusible yarn and yarn 139 is a fusible yarn, knit component 130 may be heated to fuse knit component 130 after the knitting process.

The portion of knitted component 260 illustrated in FIGS. 21A-21I has a rib-knit fabric construction with regular, uninterrupted courses and wales. That is, portions of knitted component 260 do not have areas of mesh similar to knit zones 163-165 of mesh or areas of mock mesh similar to knit zones 166 and 167 of mock mesh, for example. To form knit zones 163-165 of mesh in any of knitted components 150 and 260, the needle bed 201 is swung and the needles are swung from front to back and from back to front at different swing positions. A combination with the transfer of the floor 201 is utilized. To form mock mesh areas similar to mock mesh knit zones 166 and 167, a combination of needle bed shaking and front to back needle bed 201 transfer is utilized.

Courses in the knitted component are generally parallel to each other. Given that most of the inlaid strands 152 follow a course within the knit element 151, one might think that the various sections of the inlaid strands 152 are parallel to each other. For example, referring to FIG. 9, some sections of inlaid strand 152 extend between edges 153 and 155 and other sections extend between edges 153 and 154 . As such, the various sections of inlaid strands 152 are not parallel. The concept of forming darts may be utilized to impart this non-parallel configuration to the inlaid strands 152 . More specifically, courses of varying lengths may be formed to effectively interpose wedge-shaped structures between sections of inlaid strands 152 . As such, the structure formed in the knitted component 150 may be achieved from the dart forming process when the various sections of the inlaid strands 152 are not parallel.

Most of the inlaid strands 152 follow the course within the knit element 151, but some sections of the inlaid strands 152 follow the wales. For example, sections of inlaid strands 152 adjacent and parallel to inner edge 155 follow the wales. This may be accomplished by first inserting a section of inlaid strand 152 along a portion of the course at the point where the inlaid strand 152 is to follow the wale. The inlaid strand 152 is then reversed to move the inlaid strand 152 out of the track and complete the course. Then, as the course is being formed, the inlaid strand 152 is reversed again to move the inlaid strand 152 off the track and move to the point where the inlaid strand 152 is to follow the wale, ending the course. . This process is repeated until the inlay strand 152 extends the desired distance along the wale. A similar concept may be utilized for the inlaid strand 132 portion of the knitted component 130 .

Various procedures may be used to reduce relative movement between (a) knit element 131 and inlaid strand 132 or (b) knit element 151 and inlaid strand 152 . That is, various procedures may be utilized to prevent inlaid strands 132 and 152 from sliding, shifting, falling off, or otherwise displacing knit elements 131 and 151 . For example, one or more yarns formed from a thermoplastic polymer material may be fused to inlaid strand 132 to prevent movement between inlaid strands 132 and 152 and knit elements 131 and 151 . Additionally, inlaid strands 132 and 152 may be anchored to knit elements 131 and 151 as they are fed regularly to knitting needles as tuck elements. That is, inlay strands 132 and 152 may be knit into a tuck knit at points along their length to secure inlay strands 132 and 152 to knit elements 131 and 151 and prevent movement of inlay strands 132 and 152. Good (eg, once every centimeter).

After the knitting process described above, various manipulations may be performed to improve the properties of any of knitted components 130 and 150 . For example, a water repellent coating or other water resistant treatment may be applied to limit the ability of the knit structure to absorb and retain moisture. As another example, steam may be applied to knitted components 130 and 150 to improve resiliency and induce yarn fusing. Yarns 138 may be non-fusible yarns and yarns 139 may be fusible yarns, as described above with respect to FIG. 8B. Upon application of steam, yarn 139 melts or otherwise softens, thereby transitioning from a solid state to a softened or liquid state, and upon sufficient cooling to transition from a softened or liquid state to a solid state. You may do so. Thus, the yarns 139 can be, for example, (a) one portion of the yarns 138 to another portion of the yarns 138, (b) the yarns 138 and the inlaid strands 132 to each other, or (c) another element (e.g., logo , trademarks, and tags with cautionary and material information) may be utilized to join the knitted component 130 . Accordingly, the process of applying steam may be utilized to induce fusing of the yarns in knitted components 130 and 150 .

While the procedures associated with the steaming process may vary widely, one method involves pinning one of the knitted components 130 and 150 to a jig while steaming. An advantage of pinning one of knitted components 130 and 150 to a jig is that the finished dimensions of particular areas of knitted components 130 and 150 can be controlled. For example, pins on the jig may be arranged to hold the knitted component 130 in an area corresponding to the peripheral edge 133 . By maintaining the particular dimensions of perimeter 133 , perimeter 133 will have the correct length for part of the lasting process that joins upper 120 to sole structure 110 . Thus, the printed areas of knitted components 130 and 150 may be utilized to control the finished dimensions of knitted components 130 and 150 after the steaming process.

The knitting process described above to form knitted component 260 may be applied to manufacture knitted components 130 and 150 of footwear 100 . Knitting processes may also be applied to manufacture a variety of other knitted components. That is, knitting processes utilizing one or more combination feeders or other reciprocating feeders may be used to form various knitted components. Thus, knitted components formed by the above-described knitting process or similar processes may be used in other types of apparel (e.g., shirts, pants, socks, outerwear, underwear), athletic articles (e.g., golf bags). , baseball and football gloves, soccer ball restraining structures), containers (eg pack packs, bags), and upholstery for furniture (eg chairs, sofas, car seats). Knitted components may also be used in bed coverings (eg, sheets, blankets), table coverings, towels, flags, tents, sails and parachutes. Knitted components are used in structures for the automotive and aerospace industries, filter materials, medical fabrics (e.g. bandages, swabs, grafts), geotextiles for embankment reinforcement, agrotextiles for crop protection , and industrial technical textiles, including industrial clothing that protects or insulates from heat and radiation. Thus, knitted components formed from the knitting process described above or similar processes may be incorporated into a variety of products for both personal and industrial purposes.

The invention is disclosed above and in the accompanying drawings with reference to various configurations. The purpose served by the disclosure, however, is to provide examples of the various features and concepts related to the invention, not to limit the scope of the invention. Those skilled in the art will appreciate that numerous variations and modifications can be made to the above-described arrangements without departing from the scope of the invention as defined in the appended claims.

Claims (19)

A knit component,
A course having a plurality of intermeshed loops having a flat knit structure formed using needles from two needle beds, said course including intermeshed loops formed from a first yarn. a course having one portion, the course having a second portion comprising intermeshed loops formed from a second yarn;
The second yarn forms an inlaid strand within the first portion of the course, the inlaid strand having one of the plurality of intermeshed loops of the first yarn being one of the inlaid strands. extending through the weft knit structure within the first portion such that another intermeshed loop of the first yarn lies on another side of the inlaid strand;
the inlaid strand is inserted over the entire length of the first portion of the course;
Knitted elements. said first portion of said course and said second portion of said course form a continuous course of said knitted component;
A knitted component according to claim 1 . wherein said course is a first course, said inlaid strand is further inserted within a second course, said second course being a different course than said first course;
A knitted component according to claim 1 . the second course includes intermeshed loops intermeshed with the intermeshed loops of the first course;
4. A knitted component according to claim 3. a first portion of the second yarn forms the intermeshed loops of the first course and a second portion of the second yarn forms the inlaid strand;
4. A knitted component according to claim 3. a loop formed from the second yarn extends from the first portion of the second yarn to the second portion of the second yarn;
6. A knitted component according to claim 5. said first yarn being dispensed from a first feeder of a knitting machine and said second yarn being dispensed from a second feeder of said knitting machine;
A knitted component according to claim 1 . a first course having a first plurality of intermeshed loops formed of a first yarn, each intermeshed loop of said first course excluding a second yarn; one course includes a flat knit structure formed using needles from two needle beds;
a second course having a second plurality of intermeshed loops formed of said second yarn, said second course being a different course than said first course; course and
an inlaid strand inserted within said first course, said second yarn forming said inlaid strand and one interlocked loop of said first yarn on one side of said inlaid strand; an inlaid strand located and another intermeshed loop of said first yarn being located on another side of said inlaid strand;
having
Knitted elements. wherein said first plurality of interdigitated loops comprises loops interdigitated with loops of said second plurality of interdigitated loops;
9. A knitted component according to claim 8. a first portion of the second yarn forms the second intermeshed loops and a second portion of the second yarn forms the inlaid strand;
9. A knitted component according to claim 8. a loop formed from the second yarn extends from the first portion of the second yarn to the second portion of the second yarn;
11. Knitted component according to claim 10. said first yarn being dispensed from a first feeder of a knitting machine and said second yarn being dispensed from a second feeder of said knitting machine;
9. A knitted component according to claim 8. A course having a plurality of intermeshed loops, said course having a first portion comprising a weft knit structure formed using needles from two needle beds having a first yarn; ,
An inlaid strand formed of a second yarn, said inlaid strand having one intermeshed loop of said first yarn on one side of said inlaid strand and another of said first yarn. an inlaid strand extending through the weft knit structure such that the interlocked loops are on different sides of the inlaid strand;
has
a second portion of the course is formed of the second yarn such that the second portion of the course has a flat knit structure formed using needles from two needle beds;
Knitted elements. said first portion of said course and said second portion of said course form a continuous course of said knitted component;
14. The knitted component of Claim 13. wherein said course is a first course, said inlaid strand is further inserted within a second course, said second course being a different course than said first course;
14. The knitted component of Claim 13. the second course includes intermeshed loops intermeshed with the intermeshed loops of the first course;
16. A knitted component according to claim 15. a first portion of the second yarn forms the intermeshed loops of the first course and a second portion of the second yarn forms the inlaid strand;
16. A knitted component according to claim 15. a loop formed from the second yarn extends from the first portion of the second yarn to the second portion of the second yarn;
18. The knitted component of Claim 17. said first yarn being dispensed from a first feeder of a knitting machine and said second yarn being dispensed from a second feeder of said knitting machine;
14. The knitted component of Claim 13.

Images